Continuous linear production in a selective laser sintering system

ABSTRACT

A method and apparatus for forming objects. Layers of precursor material may be placed on top of each other. The layers of precursor material may be selectively cured as the layers of precursor material are placed on top of each other to form an object and a frame associated with the object.

This application is a divisional application of U.S. patent applicationSer. No. 12/886,631, filed Sep. 21, 2010, now U.S. Pat. No. 9,522,501.

BACKGROUND INFORMATION

1. Field

The present disclosure relates generally to manufacturing objects and,in particular, to a method and apparatus for manufacturing objects usingadditive manufacturing. Still more particularly, the present disclosurerelates to a method and apparatus for manufacturing objects usingselective laser sintering.

2. Background

Manufacturing of objects may be performed in a number of different ways.For example, objects, such as aircraft parts, may be manufactured usingadditive manufacturing. Additive manufacturing may be a process ofjoining materials to make objects. These objects may be made by usingmodels of the desired object.

Additive manufacturing may be performed using various technologies. Forexample, without limitation, an aerosol jetting system may send a streamof particles towards a substrate. The particles on the substrate may beheated to a temperature to cause the particles to adhere to each other.

As another example, electron beams may be used to melt a metal powderlayer in a desired pattern. Additional layers may be placed and meltedon the layers to form the object.

With selective laser sintering, a laser system may direct a laser beamto selectively heat portions of the layer of powder to form a portion ofthe object. Additional layers of powder may be placed on the priorlayers and heated to form the object.

Although additive manufacturing may provide for rapid production ofparts, this type of manufacturing may not be suitable for all types ofparts. For example, without limitation, additive manufacturing my oftenbe used to generate prototypes of parts. Additionally, additivemanufacturing may be limited by the cost of systems used to make parts.Further, additive manufacturing may also be limited in terms of thetypes of parts made based on an ability of the different systems to makeparticular parts.

As a result, the expense and time savings provided by additivemanufacturing may not be realized as often as desired. When additivemanufacturing cannot be used, more traditional manufacturing systems,such as the use of molds to form parts or dyes for use with presses, maybe employed. These types of systems, however, may have undesired leadtimes to form the molds and dies, as well as the expense of specializedequipment to manufacture the parts.

Therefore, it would be advantageous to have a method and apparatus thattakes into account one or more of the issues discussed above, as well asother possible issues.

SUMMARY

In one advantageous embodiment, a method may be present for formingobjects. Layers of precursor material may be placed on top of eachother. The layers of precursor material may be selectively cured as thelayers of precursor material are placed on top of each other to form anobject and a frame associated with the object.

In another advantageous embodiment, a method may be present for formingaircraft parts. Layers of precursor material may be placed on a basestructure for a frame. The layers of precursor material may be selectedfrom one of a powder, a liquid, a metal powder, a ceramic powder, and aplastic powder. The layers of precursor material may be selectivelycured using a curing system after placing the layers of precursormaterial on the base structure to form a portion of an aircraft part anda portion of the frame to form a prior layer of precursor material. Thecuring system may be selected from one of a heating system, a laser, andan electron beam. The frame may be moved to allow a new layer ofprecursor material to be placed on the prior layer of precursor materialin the layers of precursor material that may have been selectivelycured. The new layer of precursor material may be placed on the priorlayer of precursor material. A determination may be made as to whether anew base structure in the frame is needed. The new layer of precursormaterial may be selectively cured to form an additional portion of theaircraft part and a portion of the new base structure in response to thedetermination that the new base structure is needed. In response to thedetermination that the new base structure is needed, the steps of movingthe frame to allow the new layer of precursor material to be placed onthe prior layer of precursor material in the layers of precursormaterial that has been selectively cured, placing the new layer ofprecursor material on the prior layer of precursor material, andselectively curing the new layer of precursor material to form a portionof the object and the portion of the new base structure may be repeateduntil the base structure is completed. In response to an absence of thedetermination that the new base structure is needed, the new layer ofprecursor material may be selectively cured to form the additionalportion of the aircraft part without forming the new base structure. Inresponse to the absence of the determination that the new base structureis needed, the steps of moving the frame to allow the new layer ofprecursor material to be placed on the prior layer of precursor materialin the layers of precursor material that has been selectively cured,placing the new layer of precursor material on the prior layer ofprecursor material, and selectively curing the new layer of precursormaterial to form the portion of the object without the new basestructure may be repeated until the new base structure is needed. Adesired temperature for the portion of the aircraft part may bemaintained in different locations in the chamber as the aircraft part isformed using a plurality of heating and cooling elements. The uncuredprecursor material may be cooled to change a density of the uncuredprecursor material such that a flow of gas through the precursormaterial is reduced. Each portion of the aircraft part may be separatedfrom an associated base structure connected to each portion of theaircraft part using a separation system.

In yet another advantageous embodiment, an apparatus may comprise achamber, a curing system, and a movement system. The curing system maybe configured to cure portions of layers of precursor material depositedin the chamber to form an object and a frame connected to the object.The movement system may be configured to engage the frame and move theframe and the object connected to the frame as a new layer of precursormaterial is placed on a prior layer of precursor material.

In a further advantageous embodiment, a laser sintering apparatus maycomprise a chamber, a curing system, a movement system, a precursordeposition system, a temperature control system, a separation system,and a recycling system. The curing system may be configured to cureportions of layers of precursor material deposited in the chamber toform an aircraft part and a frame connected to the aircraft part. Theframe may comprise a plurality of base structures and a plurality ofconnectors and may be configured to support the aircraft part duringformation of the aircraft part in the chamber. The curing system may beselected from at least one of a heating system, a laser, and an electronbeam. The movement system may be configured to engage the frame and movethe frame connected to the aircraft part as a new layer of precursormaterial may be placed on a prior layer of precursor material. Themovement system may comprise a plurality of gears having first teethconfigured to engage second teeth formed on sides of the plurality ofbase structures. The precursor deposition system may be configured todeposit the new layer of precursor material on the prior layer ofprecursor material. The temperature control system may be configured tocontrol a temperature of at least one of the aircraft part and theframe. The temperature control system may comprise a plurality ofheating and cooling elements configured to heat and cool walls of achamber to control the temperature of at least one of the aircraft partand the frame and in which the temperature control system may beconfigured to cool uncured precursor material that has been deposited tochange a density of the uncured precursor material such a flow of gasthrough the precursor material is reduced. The separation system may beconfigured to separate the aircraft part from a base structure. Theseparation system may be configured to separate the aircraft part fromthe base structure as the base structure and the aircraft part are movedby the movement system. The recycling system may be configured torecycle portions of the layers of precursor material that remainuncured. The layers of precursor material may be selected from one of apowder, a liquid, a metal powder, and a ceramic powder.

The features, functions, and advantages may be achieved independently invarious embodiments of the present disclosure or may be combined in yetother embodiments in which further details may be seen with reference tothe following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the advantageousembodiments are set forth in the appended claims. The advantageousembodiments, however, as well as a preferred mode of use, furtherobjectives, and advantages thereof, will best be understood by referenceto the following detailed description of an advantageous embodiment ofthe present disclosure when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is an illustration of an aircraft manufacturing and servicemethod in accordance with an advantageous embodiment;

FIG. 2 is an illustration of an aircraft in which an advantageousembodiment may be implemented;

FIG. 3 is an illustration of a manufacturing environment in accordancewith an advantageous embodiment;

FIG. 4 is an illustration of a manufacturing environment in accordancewith an advantageous embodiment;

FIG. 5 is an illustration of manufacturing objects in an additivemanufacturing system in accordance with an advantageous embodiment;

FIG. 6 is an illustration of a portion of a frame connected to a portionof an object in accordance with an advantageous embodiment;

FIG. 7 is an illustration of a portion of a movement system engaging abase structure for a frame in accordance with an advantageousembodiment;

FIG. 8 is an illustration of a portion of a movement system engaging aportion of a frame in accordance with an advantageous embodiment;

FIG. 9 is an illustration of a cutter for a separation system inaccordance with an advantageous embodiment;

FIG. 10 is an illustration of a flowchart of a process for manufacturingobjects in accordance with an advantageous embodiment; and

FIG. 11 is an illustration of a flowchart of a process for manufacturingan object in accordance with an advantageous embodiment.

DETAILED DESCRIPTION

Referring more particularly to the drawings, embodiments of thedisclosure may be described in the context of aircraft manufacturing andservice method 100 as shown in FIG. 1 and aircraft 200 as shown in FIG.2. Turning first to FIG. 1, an illustration of an aircraft manufacturingand service method is depicted in accordance with an advantageousembodiment. During pre-production, aircraft manufacturing and servicemethod 100 may include specification and design 102 of aircraft 200 inFIG. 2 and material procurement 104.

During production, component and subassembly manufacturing 106 andsystem integration 108 of aircraft 200 in FIG. 2 takes place.Thereafter, aircraft 200 in FIG. 2 may go through certification anddelivery 110 in order to be placed in service 112. While in service 112by a customer, aircraft 200 in FIG. 2 may be scheduled for routinemaintenance and service 114, which may include modification,reconfiguration, refurbishment, and other maintenance or service.

Each of the processes of aircraft manufacturing and service method 100may be performed or carried out by a system integrator, a third party,and/or an operator. In these examples, the operator may be a customer.For the purposes of this description, a system integrator may include,without limitation, any number of aircraft manufacturers andmajor-system subcontractors; a third party may include, withoutlimitation, any number of venders, subcontractors, and suppliers; and anoperator may be an airline, leasing company, military entity, serviceorganization, and so on.

With reference now to FIG. 2, an illustration of an aircraft is depictedin which an advantageous embodiment may be implemented. In this example,aircraft 200 is produced by aircraft manufacturing and service method100 in FIG. 1 and may include airframe 202 with a plurality of systems204 and interior 206. Examples of systems 204 include one or more ofpropulsion system 208, electrical system 210, hydraulic system 212, andenvironmental system 214. Any number of other systems may be included.Although an aerospace example is shown, different advantageousembodiments may be applied to other industries, such as the automotiveindustry.

Apparatus and methods embodied herein may be employed during at leastone of the stages of aircraft manufacturing and service method 100 inFIG. 1. As used herein, the phrase “at least one of”, when used with alist of items, means that different combinations of one or more of thelisted items may be used and only one of each item in the list may beneeded. For example, “at least one of item A, item B, and item C” mayinclude, for example, without limitation, item A or item A and item B.This example also may include item A, item B, and item C or item B anditem C.

In one illustrative example, components or subassemblies produced incomponent and subassembly manufacturing 106 in FIG. 1 may be fabricatedor manufactured in a manner similar to components or subassembliesproduced while aircraft 200 is in service 112 in FIG. 1. As yet anotherexample, a number of apparatus embodiments, method embodiments, or acombination thereof may be utilized during production stages, such ascomponent and subassembly manufacturing 106 and system integration 108in FIG. 1. A number, when referring to items, means one or more items.For example, a number of apparatus embodiments is one or more apparatusembodiments. A number of apparatus embodiments, method embodiments, or acombination thereof may be utilized while aircraft 200 is in service 112and/or during maintenance and service 114 in FIG. 1. In particular, thedifferent advantageous embodiments may be used to manufacture partsduring one or more of these stages. The use of a number of the differentadvantageous embodiments may substantially expedite the assembly ofand/or reduce the cost of aircraft 200.

The different advantageous embodiments recognize and take into account anumber of considerations. For example, without limitation, the differentadvantageous embodiments recognize and take into account that currentselective laser sintering machines may be capable of building parts ofvarious shapes, sizes, and/or configurations. The dimensions of theseparts may, however, be limited based on the size and shape of thechamber. For example, without limitation, the size of the part may beconfined in two axes based on the walls of the chamber in which theselective laser sintering is performed. Another axis may be based on themovement of the platform with respect to the walls.

The different advantageous embodiments recognize and take into accountthat the size of the part may be increased by scaling the size of thechambers. However, this type of manufacturing may be limited based onthe cost and space needed for larger chambers. The differentadvantageous embodiments recognize and take into account that it wouldbe advantageous to have a capability to manufacture larger parts withoutneeding to have larger chambers to hold the parts as the parts areformed.

For example, without limitation, the different advantageous embodimentsrecognize and take into account that some components may have lengths ofabout 20 feet or more. More specifically, a duct in a section of afuselage may have a length of about 20 to about 40 feet. This length maybe based on a length of a portion of a fuselage made out of a compositematerial. The different advantageous embodiments recognize and take intoaccount that it would be desirable to make a duct that has the length ofthe section of a fuselage instead of joining pieces to each other toform the duct in the fuselage. The different advantageous embodimentsrecognize and take into account that by making the duct in a singlepiece for a section of a fuselage, the amount of time and expense neededto install a duct in a portion of a fuselage may be decreased.

For example, without limitation, the different advantageous embodimentsrecognize and take into account that current ducts for environmentalcontrol systems in fuselages may be formed by different cross-sectionsthat may be bonded or fastened to each other. This type of assembly mayrequire lead time, costs, and may have design limitations. Further,additional labor may be needed to assemble the parts.

Thus, the different advantageous embodiments provide a method andapparatus for manufacturing objects. The different advantageousembodiments may place layers of precursor material on top of each other.The layers of precursor material may be selectively cured as they areplaced on top of each other to form a portion of an object and a portionof a frame associated with the object.

With reference now to FIG. 3, an illustration of a manufacturingenvironment is depicted in accordance with an advantageous embodiment.In these illustrative examples, manufacturing environment 300 may beused to manufacture objects. In these illustrative examples, objects 302may take the form of parts 304. Parts 304 may be aircraft parts 306 foruse in aircraft 200 in FIG. 2. These parts may be manufactured duringvarious phases of aircraft manufacturing and service method 100 in FIG.1.

In these illustrative examples, objects 302 may be manufactured usingadditive manufacturing system 308. As depicted, additive manufacturingsystem 308 may comprise chamber 310, curing system 312, precursordeposition system 314, movement system 316, separation system 318,recycling system 320, and temperature control system 322.

Chamber 310 may be associated with curing system 312, precursordeposition system 314, movement system 316, separation system 318, andrecycling system 320. In these examples, object 324 may be formed insidechamber 310.

Object 324 may be formed and supported using frame 326. Frame 326 may beassociated with object 324. A first component may considered to beassociated with a second component by being secured to the secondcomponent, bonded to the second component, fastened to the secondcomponent, and/or connected to the second component in some othersuitable manner. The first component also may be connected to the secondcomponent using a third component. The first component may also beconsidered to be associated with the second component by being formed aspart of and/or an extension of the second component.

In these examples, frame 326 may be directly connected to object 324.Frame 326 may be formed as object 324 is formed within additivemanufacturing system 308. As depicted, frame 326 may be comprised ofplurality of base structures 327 and plurality of connectors 329.Plurality of connectors 329 may be used to connect plurality of basestructures 327 to each other and/or to object 324. Base structureswithin plurality of base structures 327 and connectors within pluralityof connectors 329 may be added to frame 326 as object 324 is formed. Inthis manner, frame 326 may grow as object 324 grows within additivemanufacturing system 308.

Object 324 may be formed by processing layers 331 of precursor material330. Precursor material 330 may take a number of different forms. Forexample, without limitation, precursor material 330 may be selected fromone of powder 334, liquid 336, and other suitable forms of precursors.In these illustrative examples, precursor material 330 may be describedin the form of powder 334. Additionally, precursor material 330 may bemade from a number of different types of materials. For example, withoutlimitation, precursor material 330 may be in the form of at least one ofceramic 338, plastic 340, metal 342, and other suitable types ofmaterials.

In these illustrative examples, layers 331 of precursor material 330 maybe placed on top of each other. Layers 331 of precursor material 330 maybe selectively cured using curing system 312 as layers 331 of precursormaterial 330 are placed on top of each other to form object 324 andframe 326.

For example, without limitation, precursor deposition system 314 mayplace layer 328 of precursor material 330 onto base structure 332 inplurality of base structures 327. Depending on the type of precursormaterial 330 used, layer 328 may cover all of base structure 332. Forexample, without limitation, when precursor material 330 takes the formof powder 334, layer 328 may cover all of base structure 332. Whenprecursor material 330 takes the form of liquid 336, layer 328 may beplaced onto base structure 332 in a pattern for object 324 such thatportions of base structure 332 may not be covered by liquid 336. Asstated above, these illustrative examples are described with precursormaterial 330 taking the form of powder 334.

In these illustrative examples, base structure 332 may be formed priorto any curing being performed by curing system 312. For example, withoutlimitation, base structure 332 may be a first base structure inplurality of base structures 327 for frame 326. Base structure 332 maybe a solid structure having a capability to support formation of object324 within additive manufacturing system 308.

Layer 328 of precursor material 330 may be selectively cured usingcuring system 312 to form portion 344 of object 324. Curing system 312may take a number of different forms. For example, without limitation,curing system 312 may include at least one of laser system 346, electronbeam system 348, and other suitable types of curing systems.

In these illustrative examples, when curing system 312 takes the form oflaser system 346, laser beam 350 may be selectively applied to parts 351of layer 328 of precursor material 330 to selectively cure parts 351 oflayer 328 to form portion 344 of object 324. Further, curing parts 351of layer 328 may also connect portion 344 of object 324 to basestructure 332.

After layer 328 of precursor material 330 has been selectively cured toform portion 344 of object 324, base structure 332 for frame 326 withportion 344 of object 324 may be moved by movement system 316 in adirection away from curing system 312.

Thereafter, precursor deposition system 314 may place new layer 352 ofprecursor material 330 on the prior layer of precursor material, layer328. A determination is made as to whether a new base structure isneeded for frame 326 to support object 324. In response to adetermination that a new base structure is needed, curing system 312selectively cures new layer 352 of precursor material 330 to formportion 359 of new base structure 354 and portion 356 of object 324.Further, additional layers 353 of precursor material 330 may be placedonto frame 326 and cured to form portions 355 of object 324 and completethe formation of new base structure 354.

In these illustrative examples, at least one of portion 356 and portions355 of object 324 may be associated with new base structure 354. Inother words, at least one of portion 356 and portions 355 may beconnected to new base structure 354. This connection may be made in amanner that provides additional support for object 324 within curingsystem 312. For example, without limitation, this connection may be madeby curing at least one of new layer 352 and additional layers 353 suchthat number of connectors 357 in plurality of connectors 329 is formed.Number of connectors 357 may connect at least one of portion 356 andportions 355 of object 324 with new base structure 354.

If new base structure 354 is not needed, then new layer 352 isselectively cured using curing system 312 to form portion 356 of object324 in new layer 352 without forming new base structure 354.

Each time a layer in layers 331 is selectively cured, frame 326 may bemoved away from curing system 312 in a direction along axis 358. Axis358 may extend through chamber 310. The movement of base structure 332away from curing system 312 along axis 358 may occur after selectivelycuring a prior layer of precursor material 330. Base structure 332 maybe moved away from curing system 312 along axis 358 prior to placing newlayer 352 of precursor material 330 in these examples.

These steps can be repeated until object 324 may be completed. In otherwords, the steps of moving base structure 332 away from curing system312, placing new layer 352 on a prior layer of precursor material, andselectively curing new layer 352 may be repeated to complete formingobject 324. In forming object 324, base structure 332, new basestructure 354, and any other base structures that may be formed becomepart of frame 326.

In these illustrative examples, movement system 316 may be configured toengage and move frame 326 through moving plurality of base structures327. In these illustrative examples, movement system 316 may comprise,without limitation, gears 364, which may be turned by motor 366. Gears364 may have teeth 368. Teeth 368 may engage teeth 370 formed inplurality of base structures 327.

When object 324 is complete or partially complete, separation system 318may separate plurality of base structures 327 from object 324. In theseillustrative examples, separation system 318 may include cutters 372,which may be rotated by motor 374. Cutters 372 may engage plurality ofbase structures 327 in a manner that separates plurality of basestructures 327 from object 324.

Cutters 372 may include, for example, without limitation, lasers, jetsfilled with abrasive media, blades, and/or other suitable types ofdevices. Plurality of base structures 327 and precursor material 330 maybe recycled by recycling system 320. Some or all of precursor material330 that has not been selectively cured may be returned to precursordeposition system 314 for use in manufacturing additional objects.

In these depicted examples, frame 326 may be considered as a chamberwithin chamber 310 that can be formed and taken apart as object 324and/or other objects are being formed. In this manner, with the use offrame 326, a larger chamber than chamber 310 may be unnecessary.

In these illustrative examples, temperature control system 322 maycomprise at least one of number of heating elements 376 and number ofcooling elements 378 located in different locations in association withchamber 310. Temperature control system 322 may maintain temperatureprofile 380 for object 324 along axis 358. Temperature profile 380 maybe a gradient of temperatures along frame 326. Temperature profile 380may control the expansion or contraction of plurality of base structures327 and object 324 during or after curing by curing system 312.

Further, in these depicted examples, number of heating elements 376 andnumber of cooling elements 378 may be used to cool uncured precursormaterial 384 to increase the density of uncured precursor material 384.In these examples, this increase in the density of uncured precursormaterial may cause uncured precursor material 384 to not move in anundesired manner through chamber 310 and/or out of chamber 310. In otherwords, uncured precursor material 384 may stick together when thedensity of uncured precursor material 384 is increased.

Additionally, plurality of base structures 327 and precursor material330 that is cured may be cooled during this process in addition touncured precursor material 384. This cooling may increase the density ofprecursor material 330 such that a flow of gas through precursormaterial 330 may be reduced. The gas may be, for example, withoutlimitation, oxygen. This reduction in the flow of oxygen throughprecursor material 330 may reduce decreases in the mechanicalperformance of object 324 caused by the flow of gas through precursormaterial 330.

For example, as plurality of base structures 327 cools, plurality ofbase structures 327 may shrink in size. The shrinking in size mayprevent teeth 370 from engaging teeth 368. Temperature control system322 may maintain a temperature that is configured to allow teeth 368 tocontinue to engage teeth 370 throughout chamber 310.

Additionally, in some illustrative examples, gears 364 may beselectively repositioned to take into account a change in size inplurality of base structures 327. Additionally, chamber 310 may betapered along axis 358 to take into account reduction in the size ofplurality of base structures 327 from cooling.

In these illustrative examples, recycling system 320 may collect basestructures within plurality of base structures 327 and/or precursormaterial 330 to be recycled. For example, without limitation, precursormaterial 330 left over after formation of object 324 may be collectedand reused by precursor deposition system 314 for the formation of otherobjects. Further, base structure 332 may be reused for the formation ofother objects.

In manufacturing object 324, other objects may be manufactured prior toobject 324 being completely separated from plurality of base structures327. In this manner, continuous manufacturing of objects 302 may occurwithin additive manufacturing system 308. Additionally, one of pluralityof base structures 327 may serve as base structure 332 for a new objectrather than having to place a new first base structure within chamber310 and engaging the base structure with movement system 316.

The illustration of manufacturing environment 300 in FIG. 3 is not meantto imply physical or architectural limitations to a manner in whichdifferent advantageous embodiments may be implemented. Other componentsin addition to and/or in place of the ones illustrated may be used. Somecomponents may be unnecessary in some advantageous embodiments. Also,the blocks are presented to illustrate some functional components. Oneor more of these blocks may be combined and/or divided into differentblocks when implemented in different advantageous embodiments.

For example, in some advantageous embodiments, additional additivemanufacturing systems, in addition to additive manufacturing system 308,may be present in manufacturing environment 300. In still otheradvantageous embodiments, objects 302 may take forms other than parts304 or aircraft parts 306. For example, without limitation, objects 302may take the form of automobile parts, ship parts, pipes, tubing, tools,furniture, and/or other suitable types of objects.

Further, in other illustrative examples, movement system 316 maycomprise devices in addition to or in place of gears 364. For example,without limitation, movement system 316 may comprise friction devices382. Friction devices 382 may include any device configured to createfriction between friction devices 382 and frame 326. This friction isused to move frame 326. For example, without limitation, frictiondevices 382 may include wheels, tracks, and/or other suitable types ofdevices.

With reference now to FIG. 4, an illustration of a manufacturingenvironment is depicted in accordance with an advantageous embodiment.Manufacturing environment 400 is an example of one implementation ofmanufacturing environment 300 in FIG. 3. In this illustrative example,additive manufacturing system 402 provides an example of one manner inwhich additive manufacturing system 308 in FIG. 3 may be implemented.

As depicted, additive manufacturing system 402 may comprise chamber 404,curing system 406, precursor deposition system 408, movement system 410,separation system 412, recycling system 414, and temperature controlsystem 416.

In these illustrative examples, chamber 404 may comprise walls 418 anddoor 420. Door 420 closes opening 422 in walls 418 of chamber 404.Curing system 406 may comprise laser system 424 in these examples.

As illustrated, movement system 410 may include gears 426, 428, 430,432, 434, 436, 438, 440, 442, and 444. In these examples, gears 426,428, 430, 432, and 434 may turn in the direction of arrow 445. Gears436, 438, 440, 442, and 444 may turn in the direction of arrow 446.

Separation system 412 may comprise cutter 448 and cutter 450. Cutter 448may turn in the direction of arrow 452, while cutter 450 may turn in thedirection of arrow 454.

Temperature control system 416 may include elements 456, 458, 460, 462,464, 466, 470, 472, 474, 476, 478, and 480. These elements may beselected from at least one of heating elements, cooling elements, andother suitable types of elements. As illustrated, recycling system 414may comprise conveyor belt 482 and powder cleanup station 484. Powdercleanup station 484 may return any reusable precursor material toprecursor deposition system 408.

With reference now to FIG. 5, an illustration of manufacturing objectsin an additive manufacturing system is depicted in accordance with anadvantageous embodiment. In this illustrative example, object 500 may bemanufactured through the placement of precursor material 502 in layers504 onto base structure 506. Portions 508 of object 500 may be formed aslayers 504 of precursor material 502 are placed onto base structure 506with laser system 424 applying laser beam 510 to selectively cureprecursor material 502.

In this illustrative example, frame 501 may support object 500 as object500 is formed. Frame 501 may comprise base structures 506, 514, 516,518, 520, 522, and 524. As depicted, a cross-sectional view of frame 501may be illustrated in this illustrative example. Further, basestructures 514, 516, 518, 520, 522, and 524 may be seen in phantom view.

With reference now to FIG. 6, an illustration of a portion of a frameconnected to a portion of an object is depicted in accordance with anadvantageous embodiment. In this illustrative example, portion 600 offrame 501 may be connected to portion 602 of object 500 in FIG. 5.

As depicted, base structure 506 may be connected to base structure 514by connector 604 and connector 606. Further, base structure 514 may beconnected to portion 602 of object 500 by connector 608 and connector610. In this manner, portion 602 of object 500 may be supported by basestructure 506 and base structure 514.

With reference now to FIG. 7, an illustration of a portion of a movementsystem engaging a base structure for a frame is depicted in accordancewith an advantageous embodiment. In this illustrative example, gear 428of movement system 410 may be seen engaging base structure 522 of frame501.

As depicted, gear 428 may have teeth 702. Base structure 522 may haveteeth 700. Gear 428 may be rotated in the direction of arrow 706, suchthat teeth 702 may engage teeth 700 on base structure 522. This rotationof gear 428 may cause base structure 522 and frame 501 to be moved alongaxis 708.

With reference now to FIG. 8, an illustration of a portion of a movementsystem engaging a portion of a frame is depicted in accordance with anadvantageous embodiment. In this illustrative example, movement system800 may be used to engage frame 501 in FIG. 5 in the place of movementsystem 410 in FIG. 4.

As depicted, movement system 800 may have track 802. Track 802 may haveteeth 806 around track 802. Teeth 806 may be configured to engage teeth808 on base structure 520, teeth 810 on base structure 518, and otherteeth (not shown in this view) on other base structures (not shown inthis view) for frame 501.

In this illustrative example, track 802 may be moved such that teeth 806move in the direction of arrow 804. This movement of track 802 and teeth806 may cause frame 501 with base structure 518 and base structure 520to be moved in a direction along axis 812.

With reference now to FIG. 9, an illustration of a cutter for aseparation system is depicted in accordance with an advantageousembodiment. In this illustrative example, cutter 448 for separationsystem 412 may rotate in the direction of arrow 452 to separate basestructure 514 from object 500 in FIG. 5.

As depicted, base structure 514 may be connected to connector 900 andconnector 902. Connector 900 may have connected base structure 514 tobase structure 516 in FIG. 5. Connector 902 may have connected basestructure 514 to object 500 in FIG. 5.

With reference now to FIG. 10, an illustration of a flowchart of aprocess for manufacturing objects is depicted in accordance with anadvantageous embodiment. In this illustrative example, the process maybe implemented using additive manufacturing system 308 in manufacturingenvironment 300 in FIG. 3.

The process may begin by placing layers 331 of precursor material 330 ontop of each other (operation 1000). The process may selectively curelayers 331 of precursor material 330 as layers 331 of precursor material330 are placed on top of each other to form object 324 and frame 326associated with object 324 (operation 1002), with the processterminating thereafter.

With reference now to FIG. 11, an illustration of a flowchart of aprocess for manufacturing an object is depicted in accordance with anadvantageous embodiment. The process illustrated in FIG. 11 may beimplemented using additive manufacturing system 308 in manufacturingenvironment 300 in FIG. 3.

The process may begin by positioning base structure 332 for frame 326with respect to movement system 316 (operation 1100). In operation 1100,the process may position base structure 332 such that movement system316 may hold and/or move base structure 332 and frame 326 as frame 326grows.

Thereafter, layer 328 of precursor material 330 may be placed onto basestructure 332 (operation 1102). Next, layer 328 of precursor material330 may be selectively cured using curing system 312 (operation 1104).

Frame 326 with base structure 332 may be moved in a direction away fromcuring system 312 along axis 358 using movement system 316 (operation1106). The layer of precursor material that has been selectively curedmay be referred to as a prior layer in these examples.

Thereafter, the process may place new layer 352 of precursor material330 onto the prior layer of precursor material 330 (operation 1108). Adetermination may be made as to whether a new base structure is needed(operation 1110). In response to a determination that a new basestructure is needed, new layer 352 of precursor material 330 may beselectively cured to form portion 356 of object 324 and portion 359 ofnew base structure 354 (operation 1112).

A determination may be made as to whether new base structure 354 hasbeen completed (operation 1114). If new base structure 354 has not beencompleted, frame 326 may be moved in a direction away from curing system312 along axis 358 using movement system 316 (operation 1116).Thereafter, another new layer of precursor material 330 may be placedonto the prior layer of precursor material 330 (operation 1118). Inoperation 1118, the prior layer of precursor material 330 is new layer352 that was selectively cured in operation 1112. The new layer ofprecursor material 330, in operation 1118, is a different layer from newlayer 352 in operation 1112.

Next, the new layer may be selectively cured using curing system 312 toform another portion of object 324 and another portion of new basestructure 354 (operation 1120). Thereafter, the process may return tooperation 1114 as described above.

With reference again to operation 1114, if new base structure 354 hasbeen completed, a determination may be made as to whether object 324 hasbeen completed (operation 1121). If object 324 has been completed, theprocess may then terminate. Otherwise, if object 324 has not beencompleted, the process may return to operation 1106 as described above.With reference again to operation 1110, if a new base structure is notneeded, new layer 352 may be selectively cured by curing system 312 toform portion 356 of object 324 without forming portion 359 of new basestructure 354 (operation 1122). Thereafter, the process may proceed tooperation 1121 as described above.

The flowcharts and block diagrams in the different depicted embodimentsillustrate the architecture, functionality, and operation of somepossible implementations of apparatus and methods in differentadvantageous embodiments. In this regard, each block in the flowchartsor block diagrams may represent a module, segment, function, and/or aportion of an operation or step. In some alternative implementations,the function or functions noted in the block may occur out of the ordernoted in the figures. For example, in some cases, two blocks shown insuccession may be executed substantially concurrently, or the blocks maysometimes be executed in the reverse order, depending upon thefunctionality involved. Also, other blocks may be added in addition tothe illustrated blocks in a flowchart or block diagram.

Thus, the different advantageous embodiments provide a method andapparatus for manufacturing objects. The different advantageousembodiments may place layers of precursor material on top of each other.The layers of precursor material may be selectively cured as they areplaced on top of each other to form a portion of an object and a portionof a frame associated with the object.

The description of the different advantageous embodiments has beenpresented for purposes of illustration and description and is notintended to be exhaustive or limited to the embodiments in the formdisclosed. Many modifications and variations will be apparent to thoseof ordinary skill in the art. Further, different advantageousembodiments may provide different advantages as compared to otheradvantageous embodiments. The embodiment or embodiments selected arechosen and described in order to best explain the principles of theembodiments, the practical application, and to enable others of ordinaryskill in the art to understand the disclosure for various embodimentswith various modifications as are suited to the particular usecontemplated.

What is claimed is:
 1. A sintering apparatus comprising: a chamber; acuring system, configured to cure portions of layers of precursormaterial, deposited in the chamber to form an aircraft part and a frame,connected to the aircraft part, wherein the frame comprises a pluralityof base structures and a plurality of connectors and is configured tosupport the aircraft part during formation of the aircraft part in thechamber and wherein the curing system is selected from at least one of aheating system, a laser, and an electron beam, and wherein the curingsystem is further configured to selectively cure a new layer of theprecursor material to form a portion of the aircraft part, being formedin the chamber, and to form a portion of a new base structure to beadded to the plurality of base structures; a movement system, configuredto engage the frame and move the frame, connected to the aircraft part,as a new layer of precursor material is placed on a prior layer ofprecursor material, wherein the movement system comprises a plurality ofgears, having first teeth configured to engage second teeth, formed onsides of the plurality of base structures; a precursor depositionsystem, configured to deposit the new layer of precursor material on theprior layer of precursor material; a temperature control system,configured to control a temperature of at least one of the aircraft partand the frame, wherein the temperature control system comprises aplurality of heating and cooling elements, configured to heat and coolwalls of the chamber to control the temperature of the at least one ofthe aircraft part and the frame and wherein the temperature controlsystem is configured to cool uncured precursor material that has beendeposited to change a density of the uncured precursor material suchthat a flow of gas through the precursor material is reduced; aseparation system, configured to separate the aircraft part from theplurality of base structures as the plurality of base structures and theaircraft part are moved by the movement system; and a recycling system,configured to recycle the portions of layers of precursor material thatremain uncured, wherein the layers of precursor material are selectedfrom one of a powder, a liquid, a metal powder, and a ceramic powder. 2.The apparatus of claim 1, wherein the separation system comprisescutters.
 3. The sintering apparatus of claim 1, wherein the separationsystem comprises cutters.
 4. The apparatus of claim 1, wherein thecuring system includes a laser disposed over the chamber.
 5. Thesintering apparatus of claim 1, wherein the curing system is the laser,and wherein the laser disposed over and directed into the chamber. 6.The sintering apparatus of claim 5, wherein an opening is disposed inthe chamber opposite the laser, and wherein the recycling system furthercomprises: a conveyor belt, located under the opening, opposite thelaser; and a powder clean-up station, configured to receive powdercarried by the conveyor belt after the powder falls through the openingand onto the conveyor belt.